I made the louvered sections out of Popsicle sticks, for the sides of the guns. Made the shocks out of dowel, and cut threads into some dowel pins for the ends.
I continued work on the front wheel guns (for lack of a better term). One of the tricky parts will be making the left side gun pivot with the wheel, via a center pivot bolt and the front tie-rod will make it turn. The right side gun will be attached to the front axle, so it will already turn with the wheel. Still need to add a little more styling, tips for the barrels, slightly recessed and bumped-out lights, etc.
Trying to get it closer to looking done for the parade next week. It’ll just be on a trailer, so don’t need to worry about making it safe for a 4 year old to ride just yet (chain-guards, brakes, etc). So knocking out a few key aesthetic details/components…
Got a pretty big hurdle out of the way, which was routing the exhaust. The real Batpod, they hid to the exhaust by running it inside the frame to further the illusion that there is no gas motor in it. But this option was easier for them since they used a 4-stroke. I’m using a 2-stroke motor, and the expansion chamber is both required, and can’t be highly modified (at least not easily). So, I took the whole Batpod and the pipe that came with the motor to a friend, Fothergill (thanks again!), who has a good welder, and who himself is a much better welder than me. We modified it to go straight down, back, then angle out. It actually goes between the frame rails under the motor, so a little hard to see what’s going on, but that’s really the point, to have it as hidden as possible.
I also began work on the foot rests. Here’s the left side one. Using thin plywood, then fiberglass cloth over that, all backed by steel. Doing them in fiberglass to save weight, and they are easier to make all the slotted holes in like the real ones have.
I put the rear hub in it’s sleeve, in the rear frame tube, then cut that rear chain to length, and did a little test of the rear jackshaft-to-chain-to-rear hub. The chain running through the top tube, around the sprocket, and back through the bottom tube to the rear sprocket, with no rubbing inside there is awesome if not shocking, haha. The action is nice and smooth, very low friction.
Did some work on the drivetrain, trying to get closer to testing the motor, chains, sprockets, jackshafts, bearings, gearing, rear hub, etc. I made the front jackshaft, which has the big sprocket driven by the motor, then turns a small sprocket which then drives the sprocket on the rear jackshaft. This front jackshaft is made from a 3/4 bolt, which I had to grind a groove into for the keyway, for the sprocket keys. It’s ready to install.
I also made one final spacer (black UHMW) for the rear hub, which helps holds the wheel bearing/race together. I greased the bearing, and assembled the rear hub. It’s finally ready for install into the rear frame tube, so I can cut that rear chain to length etc.